Water softener



Filed Dec. 17. 1926 Patented Jan. 7, 1930 UNITED STATES LEE G. DANIELS, OF ROCKFORD, ILLINOIS WATER SOFTENER Application filed December 17, 1926. Serial No. 155,385.

This invention relates to water softeners of the base exchange type and relates principally to those designed for domestic service and still more particularly the hand operated type, although certain features hereinafter referred to are applicable to water softoners of all kinds.

The more important objects of the invention are:

1. To provide a water softener of a simplilo tied and cheaper construction which, furthermore, will give better service and meet practical requirements without the usual complicated and expensive equipment, the said softener having a novel type of distributing means to insure uniform water flow throughout the cross sectional area of the bed of water softening material. The means employed comprises a single pipe, in the case of small sized units, having slots therein so graduated in sizes and so disposed along one side of the pipe the length thereof that the water discharged therefrom is positively dis-. tributed evenly without the use of baffles and other expedients otherwise required.

2. To provide a distributor pipe, as just referred to, mounted in a novel way in the wall of the water softener tank so as to permit its easy removal and replacement for the puror to permit the substitution of a new one in the event that ever becomes necessary. In connection with this feature I have also provided a pointed closure for the end of the pipe which, upon insertion through the opening in the side wall of the tank, will clear a passageway through the gravel deposited in the bottom of the tank so that it is not at all difficult to replace the pipe.

3. To provide a water softener having means in the head space therein above the bed of water softening material to cause the water injected into the head space at the time of regeneration to have a swirling action so as to better to pick up and dissolve the salt or better to assimilate the brine for passage downwardly through the bed of water softening material.

4. To provide a connection with the waste pipe vent of a water softener, a muffler whereposes of inspection and cleaning periodically by to deaden the noise incident to the rushmg of the water during the salt wash.

The foregoing and other objects of the in- Figs. 2 and 3 are horizontal sections taken on the lines 22 and 3-3 of Fig. 1 looking in the directions indicated by the arrows;

Fig. 4 is an enlarged sectional detailof the distributor pipe; I

Fig. 5 is an enlarged sectional detail of the mounting therefor;

Fig. 6 is an enlarged detail of the freefend of the pipe showing the pointed closure thereon;

Fig. 7 is an enlarged sectional detail of the waste pipe muffler; and

Fig. 8 is a fragmentary enlarged vertical section through one side of the tank illustrating the novel construction thereof.

vThe same reference numerals are applied to corresponding parts throughout the views.

The softener comprises a tank 10 preferably of an improved construction and design, as hereinafter described, and containing a bed of zeolite mineral or other" water softening material shown at 11 over a layer of gravel, indicated at 12. In the normal softening operation a pipe 13, hereinafter referred' toas a distributor pipe, introduces hard water in the gravel bed for passage upwardly through the mineral for softening. The hard water is supplied through a pipe 14 having connection with the pipe 13 through a pipe'15 extending vertically alongsidethe tank 10. The softened water is discharged from the tank through a pipe 16 communicating with an elbow connection 17 disposed in the head space, indicated at 18, above the bed of water softening material in the top of the tank 10. The normal flow during the softening operation is indicated by short arrows: hard water enters at 14, flows through communicating ports in the valve 20 water softening material. The pipe 13, as

will presently appear, distributes e water evenly throughout the cross-sectional area of the bed for uniform contact with the min= the hand lever eral, and the water in passing upwardly through the bed is softened and is supplied in this condition to the service system when it leaves the tank by way of the elbow 17 and the Pig or the purpose of regenerating the softener, salt or brine is arranged to be injected into the head space 18 throu h the neck 21. The latter has a cap 22 suitably clam ed in place by the hand screw device 23. pipe 25 provides communication between the pipe 14 and the elbow 17 when the valve 20 is shifted by means of its hand lever 26 to a position approximately at right angles to that shown. The regeneration. flow is indicated by the dot and dash arrows and is as follows: hard water entering the pipe 25 from the pi e 14 is discharged through the elbow 17 into t 1e head space 18 above the mineralin the tank. The salt or brine is picked up and dissolved or assimilated for passage" downwardly through the mineral whereby to permit the chemical exchange, commonly termed baseexchange to occur so that the exhausted mineral is revived. The waste water leaves the tank through the pipe 13 and passes upwardl v through thepipe 15 and through communicating ports in'the valve 20 to be discharged to the sewer through a waste pipe 27. Broadly speaking, no invention is claimed in the mere provision of means for. introducing hard water at one end of the tank and for discharging soft water at the other end, or in means for controlling-the direction of water flow so as to carry brine or dissolved salt through the mineral in the reverse direction from the softening flow and discharging the wastewater to the sewer. Such means. generally speaking, are well known in this art.

.owever, invention is claimed in this case in the specific improved type of distributor pipe 13, in the location and disposition oft-he elbow connection 17, as well as in other details to be described in full hereinafter.

The valve'2O is to form the subject matter of a separate application to be filed presently and it will,therefore, suffice for the present purposes briefi to refer to the more important features t ereof. It, will be noted that 26 has a pointer 28 thereon to indicate b reference to the legends on the plate 29 t e position of the valve so that the operator may readily control the operation of the softener. The position marked 1-Salt is to indicate the place to which the pointer must be moved before salt or brine may be injected. At this position the Waste pipe 27 is'in restricted communication with the pipe 15 and immediately 'upon the removal of the cap 22 there will be a lowering may shift the valve to bring the pointer to the position marked Off in which position the tank is entirely shut off from communication with the supply pipe 14, the service pipe 16, and the waste pipe 27.v The softener may be left this way over night to allow the salt or brine to settle down through the bed of softening material and thoroughly regenerate the same. This practice is followed only where the mineral has been thoroughly exhausted and it is desired to insure its complete regeneration without having to use an exorbitant amount of salt or'brine. Under ordinary conditions, however, where the mineral has become only partially exhausted the valve is shifted to the position marked 2 Wash after the salt or brine has been injected. With the valve in this position the salt or brine is washed through the mineral bed at a predetermined rate, the waste water being discharged through the pipe 27, as above described. The flow is continued long enough to insure the using up of all of the salt or brine. The valve is then shifted to the position marked 3Soft which corresponds to the normal softening operation. The purpose in having the positions marked 1 to 3 in the manner described is to make it easy for the operator to put the softener through its operations by a count system in which he is not apt to make any mistake as to the se quence of operations. He commences with moving the valve to position 1, then to 2, and finally moves itback to 3 from which position he started. When the valve is brought back to its normal position after the regeneration is completed it is usually a good practiceto open a bib near the softener, as 'for example in a laundry tub, long enough. to allow all of the hard water in the head space in the softener tank to be flushed out instead of allowing this hard water to get into the service system.- The adjustments indicated at 32 and 33, as will be described in the valve application, are provided to restrict the in the valve 20 so that the rate 0 flow through ort openings 1 the tank both during regeneration and during softening may be accurately predetermined. The adjustment at 32 is made with a view to allowing the brine to be washed through only at a rate at which a complete chemical exchange between the brine and the water softening material will properly occur. The

adjustment at 33 is made with a view to preal bed at a rate beyond that at which the same can be properly softened. In other words, these adjustments adapt the softener to the available water pressure in any particular community where the softening may be installed.

The distributor pipe '13, as shown in-Figs.

,1 and 3, extends diametrically across the inside of the tank near the bottom thereof. It is'provided with transverse slots 34 on one side thereof in regularly spaced relation the length of the pipe. The slots are provided in two sets, the one set occurring in one uadrant of the cross-section of the pipe and t e other set in the other quadrant, as appears in Fig. 4. The slots are also in staggered relation, as appears in Fig. 3, so that alternate slots occur in one quadrant while intermediate slots occur in the other quadrant. With this arrangement the water issuing from theslots is fanned out sidewise both ways with respect to the pipev toward the sides of the tank, as indicated by the dotted linesin Fig. 3. The slots are preferably graduated in size from the smallest at the ends to the largest at the middle of the pipe, as best appears in Fig. 3. This produces the heaviest discharge at the middle of the tank and a lighter discharge nearer the sides of the tank as the ends of the pipe are approached. The dotted lines indicate approximately the relative extent of the sprays at different points along the pipe. For convenience in manufacture the slots are all cut with the same sized blade but the depth of the cut, and consequently the length of the slot produced, is varied so as to have the smallest slots at the ends and the largest ones at the middle of the pipe. It will be apparent that substantially the same results may be produced by varying the size of the openings in other ways. With the present construction practiea ly uniform distribution of the water flow throughout the crosssection of the bed is secured without the necessity of providing battles or using other complicateLand expensive means to secure the result desired.

I prefer to havethe distributor pipe 13 easily removable and replaceable for the purposesof inspection and cleaning which may be found necessary at regular intervals depending on the amount ofservice rendered by the softener. The pipe 13 is, therefore, externally threaded, as shown at 35, for reception in the internally threaded end 36 of a bushin 37 The latter is externally threaded for reception in a plate 38 fastened about an opening 39 provided in the side wall of the tank. The bushing '37 provides cgmmunication between the pipe 13 and the pipe 15 by way of a connection 15' threading in the bushing as shown. Whenever the pipe is to be removed tthe connection 15 is withdrawn and the bushing 37 is unthreaded so that the pipe may be pulled out from the side of the tank. It is then a simple matter to pass a saw blade of the like through each of the slots 34 to clear out any obstructions. The end of the pipe 13 is internally threaded for the reception of the externally closure 41. The latter has facets at 42 whereby the same may be threaded into the pipe or removed therefrom with a wrench. The pointed plug facilitates the entering of the pipe 13 into the tank as it serves to clear a passageway through the gravel bed. It will be apparent that the individual owner of the softener can easily attend to the mat ter of cleaning the distributor pipe as no special mechanical skill is required. In the replacing of the pipe a precaution must be taken to insure that the slots 34 will be moved to the under side of the pipe and for this reason the bushing 37 may be provided with a suitable bench mark the position of which will indicate when the slots are directed downwardly.

The elbow connection 17, as appears in Fig. 2, is preferably disposed approximately at right angles to the radius of the tank so that the water discharged therefrom during regeneration will be directed tangentially along the inside wall of the tank to give a swirling motion to the water in the head space. In this way the salt will be readily picked up and dissolved and there will be no danger of some of the salt remaining on top of the mineral bed which should have been washed down therethrough during the salt wash.

During regeneration I have found that with an ordinary vent pipe there is a certain amount of noise caused by the rushing of the water and for this reason I prefer to provide a muffler consisting of a lateral connection 43 with the T fitting 31, previously referred to, having an elbow connection with a short stand pipe 44, as shown in Fig. 7. The latter is in open communication with the atmosphere, and a certain level of water will be maintained therein during the regeneration flow. Thus, the rushing of the water through the T fitting 31 will not cause any perceptible noise. Such noise would, however, be caused if the stand pipe 44 were placed directly on the T-fitting 31 and rising therefrom as in that case the rushing water would pass by.

the lower end of the open pipe and produce either a gurgling noise or more or less of a roar depending on the rate of flow. It will thus appear that by a very simple expedient I have avoided the annoyance referred to. and

the softener is better suited for domestic use.

Softener tanks have, in the past, been short lived by reason of the corrosive action of the Water and especially of the brine. I, therefore, prefer to consgzruct the tank, as shown threaded part 40 of a pointed plug or other in Fig. 8, of a shell 45 of sheet iron or other suitable material having the requisite strength and rigidity to sustain the weight of the bed of softening material as well as to 5 withstand the water ressure active therein, the shell being provi ed with a lining 46 of another material which'resists the corrosive action oft-he water and brine. The lining may be made of sheet copper or may be provided by spraying a coatm of copper onto the inside wall of the shell, t is latter process being commercially practicable. Inv actual v practice it is preferred to use sheet copper for the lining 46 of the shell and to spray a copper coating on the end closure pieces 47,

asindicated at 48. The end closure 47 are of sheet iron or similar materia provided to fit witliin the shell 45. The pieces 47 have annular flanges 49 which are arranged to fit snugly within the shell 45 inside the lining 46 thereof and having the-lining 48 enveloping the same so as to cover the outside as well as the insidesubstantially as shown. When the parts are placed together the joints ,therebetween are sealed circumfer-- entially of the end pieces, as shown at 50, preferabl by brazing the shell with the end pieces. his will result also in a bond between thelining 48 and the lining 46. The lining 46 is swedged out to cover the sides of the openin 39, as indicated at 51 in Fig. 5, and isflare out on the outside wall of the shell, as at 52, behind the plate 38. The latter is preferabl brazed to the shell, as indicated at 53. he completed tank structure is thus lined throughout with copper and will ive much longer service than was heretofore secured with the ordinary iron tank constructions. It will also be noted that the bottom closure piece 47 is set in slightly within the shell 'so as to provide an annular apron-like flange 54 to which the legs 55 may be riveted or otherwise secured to provide a base formounting the tank.

It is believed the foregoing description conveys a clear understandin of my invention and all of its objects and a vantages. It will be apparent that the invention 1s not to be limited in its application to the particular 50' details above described as the embodiment herein shown and described has been selected merely for the purposes of illustration. I The appended claims are, therefore, to be construed to coverall legitimate modifications, adaptations and variations of the invention as will no doubt occur to any one skilled in this art.

I claim: 1. In a water softener, the combination of a tank for a bed of water softening material, said tank providing a head space therein over the material for the reception of salt or brine for regeneration, pipe connections with the upper and lower ends of said tank whereby in normal operation to admit hard water'to ieces one end of said tank and discharge soft water from the other end thereof, and a removable closure for filler opening provided-in the upper end (if said tank arran ed when removed to permit the introduction of salt or brine into the head space over the material in said tank, the upper pi e connection being arranged for directing t e incoming water tangentially along the inside wall of said tank in said head space, whereby to produce a swirling motion of the water and thus insure the immediate icking up of the salt or brine and the carrying thereof downwardly through the material.

, 2. A water softener structure as set forth in claim 1, wherein 'the tank is substantially circular in transverse section, and wherein the upper pipe connection, for the purpose set forth, has an elbow communicating therewith and disposed alongside the wall of said tank in the head space therein with its discharge end directed approximately at right.

angles to the radius 0 said tank.

3. In a water softener comprising a tank containing a bed of water softening material with a layer of gravel or equivalent coarser material provided beneath said bed, and pipe connections for the upper and lower ends of said tank arranged to admit hard water to one end andwithdraw soft water from the other end in normal operation, the lower connection comprising a pipe arranged to extend in a substantially radial direction from one side Wall of said tank imbedded in the gravel beneath the bed of water softening material, said pipe having openings through the walls thereof whereby the pipe serves as a distributor pi 'e, a bushlng threading on the outer end 0 said pipe and externally threaded for the mounting thereof in the side wall of said tank,said bushing being readily removable for removal and replacement of the pipe therewith, as for cleaning, and a closure for the inner end of said pipe, the same beingpolnted whereby to facilitate passage of the pipe through the gravel in the insertion'theres of and also facilitate the accurate ositioning thereof to permit threadin of tlie bushing in the side wall of the ta when the pipe is inserted all way.

4. In a water softener, the combination with a tank substantially circular in transverse section" and containing a bedof water softening material, and pi e connections with the upper and lower en s of said tank arranged in normal operation to admit hard water to one end of said tank and discharge soft water from the other end thereof, of an inlet pipe arranged within said tank in communication with one of said connections and extending substantially diametrically across munication with one of extending substantially diametrically across the cross section of the pipe and the other set being cut through the adjoining quadrant, the slots being spaced lengthwise of the pipe and being in staggered relationship so that alternate slots occur in one quadrant and lntermediate slots in the other quadrant, and the slots being of gradually increasing s1z e from the ends of the pipe toward the mlddle thereof for the purpose described.

5 In a water softener, the combination with a tank substantially circular in transverse section and containing a bed of water softening material, and pipe connections w1th the upper and lower ends of said tank arranged in-normal operation to admit hard water to one end .of said tank and discharge soft water fromthe other end thereof, of an inlet pipe arranged within said tank in communication with one of said connections and extending substantially diametrically across the inside of the tank, said pipe having openings therein spaced lengthwise thereof, the open ngs at both ends being smaller than the openmgs, at the middle of the pipe.

6. In a water softener, the combination wlth a tank substantially circular in transverse section and containing a bed of water softening material, and pipe connections with the upper and lower ends of said tank arranged in normal operation to admit hard water to one end of said tank and discharge soft water from the other end thereof, of an inlet pipe arranged within said tank in comsaid connections and the inside of the tank, said pipe having openings therein spaced lengthwise thereof, the openings at the ends being smaller openings at the middle of the pipe and being graduated in size from the smallest to the largest sized openings. I

7. In a water softener, the combination with a tank containing a bed of water softening material, and pipe connections for the opposite ends of said tank for admitting hard water at one end and discharging soft water at the other end in the normal softening operation, one of said connections being arranged during regeneration to serve as a salt wash inlet and the other as a waste outlet for said tank, of a waste pipe arrange to communicate with said last mentioned connection to conduct the waste from said softener, said waste pipe have a vent opening therein whereby to predetermine the lowering of the water level in said tank when the same is to be charged with salt or brine for regeneration, and a muffler communicating with said vent opening to deaden the noise incident to the regeneration flow.

8. In a water softener, the combination in a tank for a bed of water softening material, said tank providing a head space therein over the material for the, reception of salt or brine for regeneration, of pipe connections with than the the upper and lower ends of said tank whereby in normal operation to admit hard water to one end of said tank and discharge soft water from the other end thereof and whereby during regeneration to admit hard water to the head space to carry the brine therein down through the softening material, an elbow communicating with the upper pipe connection within the tank alongside the wall thereof in the head space with its discharge end directed approximately at right angles to the radius of said tank to cause the water issuing therefrom during regenerating to produce a swirling action whereby better to pick up the salt or brine for passage downwardly through the softening material, and a transverse pipe within the lower portion of said tank communicatin pipe connection, said pipe 'aving openings in the lower side thereof arranged during regeneration to receive the downcoming water and brine for discharge from the tank.

9. A water softener as set forth in claim 7 wherein the muffler comprises a laterally projecting pipe communicating with the waste pipe, and a stand pipe communicating at its lower end with the lateral pipe and open to the atmosphere at the upper end thereof. x

10. In a water softener, the combination with a tank substantially circular in transverse section and containing a bed of water softening material and pipe connections with with the lower the upper and lower ends of said tank arranged in normal operation to admit hard water'to one end of said tank and discharge soft water from the other end thereof, of an inlet pipe arranged within said tank in communication withlone of said connections and extending substantially diametrically across the inside of the tank, said pipe having transverse slots cut through the walls thereof only on one side, there being two sets of slots one set being cut through one quadrant of the cross section of the pipe and the other set being cut through the adjoining quadrant, and the slots at the middle of the pipe bein cut deeper than the slots at either end 0 the pipe for the purpose described.

In witness of the foregoing I affix my sigd nature. 

